Resealable flexible packaging

ABSTRACT

The present invention relates to a flexible packaging comprising a base layer and a film layer at least partially releasably affixed to the base layer via a pressure sensitive adhesive layer. The pressure sensitive adhesive layer comprises at least one adhesive zone and at least one adhesive-free zone extending continuously in a machine direction. The film layer is scored to form at least one pull tab which is disposed within the at least one adhesive-free zone and the base layer is scored to form at least one cavity which is disposed adjacent the at least one adhesive-free zone.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Pat. Application No.15/442,779, filed Feb. 27, 2017, entitled “RESEALABLE FLEXIBLEPACKAGING”, which is incorporated herein in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to resealable flexiblepackaging.

SUMMARY OF THE INVENTION

According to an aspect, the present invention provides a flexiblepackaging comprising a substrate base layer and a film layer at leastpartially releasably affixed to the substrate base layer via a pressuresensitive adhesive layer, wherein the pressure sensitive adhesive layercomprises at least one adhesive zone, and at least one adhesive-freezone extending continuously in a machine direction, and wherein the filmlayer is scored to form at least one pull tab which is disposed withinthe at least one adhesive-free zone, and wherein the substrate baselayer is scored to form at least one cavity which is disposed adjacentthe at least one adhesive-free zone.

According to another aspect, the present invention also provides aflexible packaging comprising a substrate base layer; and a film layerat least partially releasably affixed to the substrate base layer via apressure sensitive adhesive layer, wherein the pressure sensitiveadhesive layer comprises at least one adhesive zone, and at least oneadhesive-free zone extending continuously in a machine direction, anddisposed in the center of the film layer; wherein the film layer isscored to form a pull tab which is disposed within the at least oneadhesive-free zone, wherein the pull tab is scored down the center, suchthat it can be separated into two pull tabs; wherein the film layer isscored to form two resealable flaps which are continuous with each ofthe two pull tabs; and wherein the substrate base layer is scored toform two cavities which are disposed on opposite sides of the at leastone adhesive-free zone and are aligned with the two resealable flaps.

According to yet another aspect, the present invention also provides amethod for forming a flexible packaging comprising providing a substratebase layer in sheet form; providing a film layer in sheet form;laminating the substrate base layer to the film layer using a pressuresensitive adhesive, wherein the pressure sensitive adhesive is disposedsuch that it creates an adhesive zone and an adhesive-free zone betweenthe base layer and the film layer, and wherein the adhesive-free zoneextends continuously in a machine direction; scoring the film layer toform at least one pull tab within the adhesive-free zone and at leastone resealable flap which is continuous with the at least one pull tab;and scoring the base layer to form at least one cavity which is alignedwith the resealable flap.

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate one or more embodiments of theinvention and, together with the description, serve to explain theprinciples of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including thebest mode thereof directed to one of ordinary skill in the art, is setforth in the specification, which makes reference to the appendeddrawings, in which:

FIG. 1A is a top view of an embodiment of a transfer tape and rollstocklayer of the present invention;

FIG. 1B is a cross sectional view of an embodiment of a laminated filmof the present invention;

FIG. 2 is a top view of an embodiment of flexible packaging of thepresent invention;

FIG. 3 is a top view of another embodiment of flexible packaging of thepresent invention;

FIG. 4 is a perspective view of an embodiment of a package of thepresent invention;

FIG. 5 is a perspective view of another embodiment of a package of thepresent invention;

FIG. 6 is a top view of another embodiment of flexible packaging of thepresent invention;

FIG. 7 is a schematic view of flexible packaging made in an embodimentof the present invention.

Repeat use of reference characters in the present specification anddrawings is intended to represent the same or analogous features orelements of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Reference will now be made in detail to presently preferred embodimentsof the invention, one or more examples of which are illustrated in theaccompanying drawings. Each example is provided by way of explanation ofthe invention, not limitation of the invention. In fact, it will beapparent to those skilled in the art that modifications and variationscan be made in the present invention without departing from the scope orspirit thereof. For instance, features illustrated or described as partof one embodiment may be used on another embodiment to yield a stillfurther embodiment. Thus, it is intended that the present inventioncovers such modifications and variations as come within the scope of theappended claims and their equivalents.

A variety of food and non-food products are packaged using flexiblepackaging materials formed primarily of laminations of one or more ofpolymer films, metallized polymer films, paper, metal foil, and thelike. In many instances, packages contain products that may be used orconsumed a little at a time, and the products may be susceptible tobeing adversely affected (e.g., becoming soggy, drying out, etc.) byexposure to the surrounding environment. Accordingly, there is a desireto be able to reclose a package after its initial opening to keep theproduct that remains in the package fresh.

Various opening and reclose arrangements have been developed forflexible packaging. Often, reclosability is achieved by using apressure-sensitive adhesive label that is attached to the exterior ofthe product package, adjacent the location where the package is opened.Such labels are often formed separately from the packaging structure andare then added to the packaging structure. These types of labelstypically include a release liner, designed to protect the adhesivelayer of the label until its application onto the packaging structure.This release liner must be removed and discarded upon application ontothe packaging structure, creating unnecessary waste and expense.Additionally, separately-formed lined labels typically must have astiffness which is sufficient to dispense the label at an angle which isninety (90) degrees from the separation point of the release liner. Thislimits the thinness with which the label can be made.

Alternatively, transfer tapes can be utilized to adhere a label to apackaging film or structure without the use of a liner. Transfer tapesare typically applied to a packaging structure in the machine direction,on the center of a web. After lamination of the transfer tape andpackaging structure, the transfer tape and packaging structure can berespectively scored from top and bottom to form a resealable label.However, variability in the repeat lengths of the packaging structureand the label as well as the extensibility of the web substrates oftencauses inconsistencies in registering the pattern-applied adhesion zonesof the transfer tape against the graphics on the surface of thepackaging structure. To ensure proper registry of the transfer tape andthe packaging structure, packaging manufacturing processes often requirethe use of a servomechanism to error sense and correct.

In contrast, in an embodiment, the present invention comprises alinerless film or transfer tape that does not require registry in themachine direction during application to a packaging material. The filmor transfer tape comprises an adhesive-free zone which is continuous inthe machine direction. The film or transfer tape may by adhered to aseparate rollstock film, using a pressure sensitive adhesive to form alaminated film. The laminated film may then be scored, from top andbottom, to create a flexible packaging which comprises a resealable flapthat covers an opening in the flexible packaging and a cavity in thepackage body. The flexible packaging can then be used to form a package.By using a pull tab which is aligned with the adhesive-free zone, theend user can lift the resealable flap away from the package, remove anydesired contents from the package, and then press the resealable flapback onto the package to re-adhere the flap to the package through theuse of the pressure sensitive adhesive, thereby resealing the package.The package can thus be repeatedly opened and resealed.

The package, flexible packaging, laminated film, and transfer tape ofthe present invention can be used in connection with the packaging offood and non-food products. In various examples, the inventive packages,flexible packaging, laminated film, and transfer tape may be used tostore cookies, crackers, dry goods, cleaning products, or any otherproducts which may be opened and resealed, and would be susceptible tobeing adversely affected by exposure to the surrounding environment.

Turning to the drawings, FIG. 1A illustrates a top view, in anembodiment, of the transfer tape 11 and the substrate base layer (alsoreferred to herein as rollstock) 12 of the invention. The transfer tape11 may have an adhesive-free zone 27 and one or more adhesive 13 zones.In certain embodiments, the adhesive-free zone 27 of the transfer tape11 is continuous in the machine direction 24. In an embodiment, thetransfer tape 11 and the rollstock 12 are laminated together to form thelaminated film 10.

As is shown in the cross-sectional view of FIG. 1B, in an embodiment,the laminated film 10 of the present invention may comprise a number oflayers. In one embodiment, the laminated film 10 comprises the transfertape 11 and a rollstock layer 12. The transfer tape 11 may additionallycomprise a number of layers.

In an embodiment, the topmost or outermost layer of the transfer tape 11may comprise an optional release coating 15. In an embodiment, therelease coating 15 may be utilized if the transfer tape 11 is applied tothe rollstock 12 offline. In this embodiment, the release coating 15 maybe applied to the topside of a film 14 and may be designed to ensure thestable unwinding of the transfer tape 11 during application to therollstock 12.

In another embodiment, however, the transfer tape 11 is applied to therollstock 12 on press.In this embodiment, the transfer tape 11 may ormay not comprise a release coating 15. In the event the transfer tape 11does not comprise a release coating 15, the film 14 may compriseadditives which serve as a release.

The film 14 may comprise any flexible packaging film known in the art,including but not limited to, polymer films, metalized polymer films,papers, metal foils, polyester films, polyolefin films, polyethyleneterephthalate (PET) polypropylene (OPP), metalized polyester (MPET), anycombination thereof, or any other suitable film known in the art. Invarious embodiments, the film 14 may be a multi-layer film. In anembodiment, the film 14 comprises a pre-printed film.

As part of the transfer tape 11, the film 14 may be adjacent, on itsbottom side, an optional primer layer 16. The primer layer 16 may bedesigned to increase the holding power of any adhesive 13 utilized inthe transfer tape 11. In an embodiment, the primer layer 16 can be aliquid substance coated onto the bottom side of the film 14 and/or ontothe top side of the rollstock 12. In other embodiments, the primer layer16 may comprise a physical treatment, such as corona or flame treatment,applied to the bottom side of the film 14 and/or the top side of therollstock 12.

The bottom side of the transfer tape 11 may be releasably affixed, inareas, to the top side of a rollstock 12 through use of an adhesive 13.In an embodiment, the bottom side of the film layer 14 (or optionalprimer layer 16, as the case may be) of the transfer tape 11 is affixedin this manner to the rollstock 12. In some embodiments, adhesive 13 maycomprise a pressure sensitive adhesive (“PSA”). Any suitable PSA knownin the art may be utilized in the present invention. For example, theadhesive 13 may comprise an acrylic, a natural rubber, a syntheticrubber, a silicone, a butyl, or an ethylenevinylacetate (“EVA”).

In an embodiment, a PSA 13 is selected such that it releasably securesthe transfer tape 11 or film 14, as the case may be, to the rollstock 12in certain areas. Optionally, one or more adhesives 13 may be utilized,wherein the adhesives 13 allow the bonding of the transfer tape 11 orfilm layer 14, as the case may be, to the rollstock 12 at differentlevels of affinity. For example, an adhesive 13 having a greater bondingaffinity may be selected and utilized to adhere the transfer tape 11 orfilm 14, as the case may be, to the rollstock 12 in certain areaswherein the tamper-evident indicators 20 are positioned. The use of theadhesive 13 to secure the transfer tape 11 or film 14, as the case maybe, to the rollstock 12 creates the laminated film. In an embodiment,the adhesive 13 utilized allows transfer tape 11 or film 14, as the casemay be, and rollstock 12 to be separated and resealed multiple times bythe end user.

In an embodiment, the rollstock 12 may comprise any flexible packagingfilm known in the art, including but not limited to, polymer films,metalized polymer films, paper, metal foil, polyester film, polyolefinfilm, PET, OPP, MPET, any combination thereof, or any other suitablefilm known in the art. In various embodiments, the rollstock 12 may be amulti-layer film. In an embodiment, the rollstock 12 comprises apre-printed flexible packaging material. In an embodiment, the rollstock12 and film 14 comprise the same material.

In an embodiment, the laminated film 10 layers comprise, in order frominterior to exterior, rollstock 12, adhesive 13, an optional primerlayer 16, a film layer 14, and an optional release coating 15 as theexterior or outermost layer.

In certain embodiments, the laminated film 10 of the invention mayadditionally comprise a barrier layer, providing a barrier against thepassage of oxygen and/or moisture. In other embodiments, the laminatedfilm 10 may additionally comprise one or more metallization layers orfoil layers, which may be helpful in preventing a laser or die cuttingmachine from penetrating through the entire thickness of the film 14 orthe rollstock 12.

FIG. 2 illustrates a flexible packaging 100 of the invention, whereinthe laminated film 10 has been scored. As shown in FIGS. 1A and 2 , inan embodiment of the invention, the flexible packaging 100 may comprisean adhesive-free zone 27 between the transfer tape 11 or film 14 and therollstock 12. In an embodiment, the adhesive-free zone 27 may bedisposed continuously in the machine direction 24. In this embodiment,the adhesive-free zone 27 may be disposed continuously through both theflexible packaging 100 and a matrix or skeleton 21, which may surroundthe flexible packaging 100 while in manufacture. In this embodiment,because the adhesive-free zone 27 is disposed continuously in themachine direction 24, no registration is required in the machinedirection 24. In another embodiment, the adhesive-free zone 27 may benon-continuous through the flexible packaging 100 and/or matrix 21.

In an embodiment, the transfer tape 11 is designed such that it containsa continuous adhesive-free zone 27, in the machine direction 24. Thus,when the transfer tape 11 is applied to the rollstock 12, there is noadhesive between the two layers (the transfer tape 11 and the rollstock12) in the adhesive-free zone 27.

In an embodiment, the adhesive-free zone 27 may be disposed in thecenter of the flexible packaging 100, in the machine direction 24. Inthis embodiment, the pull tab 22, 32 may also be disposed in the centerof the flexible packaging 100, aligned with the adhesive-free zone 27.In this embodiment, the flexible packaging 100 and, respectively, thepull tab 22, 32 may be aligned in the machine direction 24, such that ifthe pull tab 22, 32 and resealable flap 42 were lifted to reveal thecavity 29, 62, such lifting would occur in the machine direction 24, asshown in FIGS. 2-5 . In this embodiment, the flexible packaging 100 mayhave at least two cavities 29. In this embodiment, the width of theadhesive-free zone 27 may be equivalent to or less than the distancebetween the at least two cavities 29.

In other embodiments, the adhesive-free zone 27 may be disposed in anyposition, left to right, within the confines of the flexible packaging100. In a particular embodiment, the adhesive-free zone 27 is disposedleft or right of center, in the machine direction 24, and is continuous(shown in FIG. 6 ). In this embodiment, the pull tab 61 may also bedisposed left or right of center, in the machine direction, and may bealigned with the adhesive-free zone 27. In a particular embodiment, theflexible packaging 100 and, respectively, the pull tab 61 may be alignedperpendicular to the machine direction 24, such that if the pull tab 61and corresponding resealable flap were lifted to reveal the cavity 62,such lifting would occur perpendicular to the machine direction 24, asshown in FIG. 6 . In an embodiment, multiple adhesive-free zones 27 arepresent within the flexible packaging 100.

In an embodiment, the adhesive-free zone 27 may be formed by deadeningor deactivating any adhesive 13 that has been applied, using any methodknown in the art. In another embodiment, the adhesive-free zone 27 maybe formed by pattern-applying the adhesive 13 to the transfer tape 11 orfilm 14 to create one or more adhesive-free zones 27. In thisembodiment, the adhesive 13 may be pattern-applied in a continuousmanner, in the machine direction 24, essentially creating one or moreadhesive lanes which define at least one continuous adhesive-free zone27 in the machine direction 24. In another embodiment, the adhesive 13may be pattern applied selectively to define alternating adhesiveportions and non-adhesive portions within the linerless label 10. In anembodiment, the adhesive-free zone 27 is created prior to application orlamination of the transfer tape 11 to the rollstock 12.

In an embodiment, the flexible packaging 100 may additionally comprisetamper-evident indicators 20. The tamper evident indicators 20 maycomprise any form known in the art used to indicate whether a packagehas been previously opened or whether the integrity of the package hasbeen compromised. In an embodiment, any tamper evident indicators 20known in the art may be utilized herein, as long as they provide anuninterrupted film area that remains on the package 40 when it isopened. In an embodiment, the tamper evident indicators 20 may includean area of weakness created, for example, by a scored, perforated, orthinned line or by forming the tamper evident indicator out of a highlyoriented material that has a tendency to split along the break line. Forexample, FIG. 2 illustrates a perforation 23 in the tamper evidentindicators 20 which creates an area of weakness such that the tamperevident indicators 20 will tend to split along the perforation 23,leaving the upper portion of the tamper evident indicators 20 on thepackage 40 when it is opened. In an embodiment, the invention utilizestamper-evident indicators 20 as more fully described in U.S. Pat.Application No. 15/017,743 to Gagne, which is incorporated by referenceherein in its entirety.

As is further shown in FIGS. 2-5 , in an embodiment, the flexiblepackaging 100 and package 40 may define multiple cavities 29 for storageof food or other products. In this embodiment, for example, there may beseparate cavities 29 on the left and right side of the package 40,optionally separated by an internal divider.

In an embodiment shown in FIGS. 2 and 4 , the flexible packaging 100 maycomprise a single pull tab 22. In this embodiment, use of the singlepull tab 22 will open both cavities 29 simultaneously. In anotherembodiment, the flexible packaging 100 may comprise a dual, or split,pull tab 32 (shown in FIGS. 3 and 5 ). In this embodiment, both sides ofpull tab 32 may be pulled simultaneously to simultaneously open each ofthe cavities 29. Alternatively, in an embodiment, pull tab 32 may beseparated into two split pull tabs, each corresponding to a separatecavity 29. Each of the split pull tabs 32 may be pulled independently toindependently open its respective cavity 39. In this embodiment, theproduct contained within each cavity 29 may be separately accessed andthe flap resealed, preserving the contents of each cavity 29 moreeffectively.

Method of Manufacture

In an embodiment, to make the laminated film 10, flexible packaging 100,and package 40, in a first step, PSA 13 (optionally, having varyinglevels of bonding affinity) may be applied between the or film 14 androllstock 12 in predetermined patterns, leaving an adhesive-free zone27. Alternatively, a transfer tape 11 may be created offline by applyingthe PSA 13 (optionally, having varying levels of bonding affinity) tothe film 14, in predetermined patterns, leaving an adhesive-free zone27. In either embodiment, the film 14 (or transfer tape 11, as the casemay be) and the rollstock 12 may then be laminated together to createthe laminated film 10.

Once the laminated film 10 is formed, precise scoring operations (laser,die cut, or any other method known in the art) may be performed oneither side of the laminated film 10. Notably, the scoring operationsneed not be in registration with the adhesive patterns due to thecontinuous adhesive-free zone 27. In an embodiment, each scoringoperation only penetrates through one layer of the laminated film 10.

More specifically, the laminated film 10, flexible packaging 100, andpackage 40 may be made, in an embodiment, in the following manner:

First, film 14 and rollstock 12 may be provided in sheet form (shown inFIG. 1A). PSA 13 may be pattern applied to the bottom surface 46 of thefilm 14 in a predetermined area. The pattern may be any suitable patternbut, in an embodiment, leaves at least one continuous adhesive-free zone27 in the machine direction 24 of the film 14. The PSA 13 may be driedat a drying station such as an oven or the like.

In an embodiment, an adhesive having a greater level of bonding affinitythan the PSA 13 may be pattern applied onto the bottom surface 46 of thefilm 14 in a predetermined area, such that the adhesive having anincreased affinity does not cover the PSA 13, does not cover the area inwhich the pull tab 22 (or 32) will be scored, and leaves at least onecontinuous adhesive-free zone 27 in the machine direction 24 of the film14. Alternatively, a transfer tape 11 may be separately prepared inaccordance with the above.

Next, as shown in FIG. 7 , the film 14 or transfer tape 11 and therollstock 12 are adhesively joined 71 via the PSA 13 to form thelaminated film 10. This may be accomplished using a laminating machinecomprising two rollers forming a nip therebetween. In an embodiment, thefilm 14 and the rollstock 12 should be substantially coextensive witheach other during the laminating process. For example, if the film 14and the rollstock 12 are rectangular, the width and length of the film14 should match the width and length of the rollstock 12. The laminatedfilm 10 may be rectangular or any shape suitable for forming the desiredflexible package 40.

Next, a roll of the laminated film 10 is fed to a first scoring station72 where an undercut 44, 63 may be scored in the rollstock 12. Theundercut 44, 63 may be formed with a laser, with a die cutting machineor by any suitable means and may extend through the entire thickness oralmost the entire thickness of the rollstock 12. In an embodiment, theundercut 44, 63 may define two or more cavities 29. In an embodiment,the undercut 44, 63 is in registration with the inside border 45 of thePSA pattern. Package integrity features 20 may be cut into the rollstock12 during this step well. In an embodiment, the undercut 44 may includea hinge 33 (shown in FIG. 3 ) such that upon opening the label, thelabel flap will hinge between the die-cuts and remain adhered to thepackage. In an embodiment, the hinge 33 may be an undercut “j-hook”hinge or an overcut back hinge, but it should be understood that anymechanism which creates a stopping point that inhibits the completeremoval of the label flap from the product package could be utilized.

The roll of laminated film 10 may then be fed to a second scoringstation 73 where an overcut 28, 64 is formed in an outer facing surfaceof the film 14. The overcut 28, 64 preferably is formed substantially inregistration with the outside border 47 of the PSA 13, although it mayoverlap the PSA 13. The overcut 28, 64 may be formed with a laser, witha die cutting machine or by any suitable means and may extend throughthe entire thickness or almost the entire thickness of the film 14. Thecompletion of the undercut 44, 63 and overcut 28, 64 create the flexiblepackaging 100. In an embodiment, at this point the matrix or skeleton 21surrounding the flexible packaging 100 may be removed and discarded.

The flexible packaging 100 can then be rolled up for use in creatingpackages 40. For example and without limitation, the flexible packaging100 can be used to wrap cookies or crackers at a cookie or crackermaking facility. After the contents are placed inside the flexiblepackaging 100, one or both ends 41 may be sealed to create the filledpackage 40. The sealing may be accomplished by crimping, folding orotherwise closing off the ends 41 and then exposing the ends 41 to atemperature sufficient to at least partially melt the flexible packaging100 so that it fuses or welds together to form a heat seal if heatsealing is used. Alternatively, and without limitation, the ends 41 maybe sealed using cold sealing.

Method of Use

FIGS. 4-5 are perspective views of embodiments of packages 40 of thepresent invention. The flexible package 40 can be opened by pulling thesingular pull tab 22 (FIG. 4 ) formed in the film 14 but not adhered tothe rollstock 12. The resealable flap 42 releases from rollstock 12 dueto the limited adhesion of the pressure sensitive adhesive 13. Morespecifically, the film 14 will break along the overcut 28 as the pulltab 22 is lifted, releasing the part of the film 14 adhered to therollstock 12 via the PSA 13. This process opens at least one cavity 29in the package 40, due in part to the presence of the undercut 44,through which the contents can be accessed. The peeling back of theresealable flap 42 serves to create the cavity 29 by removing a part ofthe rollstock layer 12 as the film layer 14 is removed or peeled back.Thus, the undercut 44 defines a location of the cavity 29 of the package40 and is formed inwardly of the overcut 28 on the resealable flap 42.In FIGS. 4-5 , the user has pulled back the resealable flap 42 to revealthe cavity 29 defined by the undercut 44.

Similarly, the flexible package 40 shown in FIG. 5 can be opened bypulling either of the separated pull tabs 32 formed in the film 14 butnot adhered to the rollstock 12. The either side of the resealable flap42 releases from rollstock 12 due to the limited adhesion of thepressure sensitive adhesive 13. This may open one of the multiplecavities 29 in the package 40, due in part to the presence of theundercut 44, through which the contents can be accessed.

In some embodiments, the pull tab 22, 32 may be defined by the overcut28, 64 to have a semi-circular or semi-elliptical shape that extendsoutwardly from the general shape of the rest of the overcut 28, 64. Inan embodiment, the inner surface of the pull tab 22, 32 and thecorresponding outer surface of the rollstock 12 may be devoid of anyadhesives, such that the pull tab 22, 32, 61 may be easily separatedfrom the package 40 (e.g., by the user sliding a finger between the pulltab 22, 32, 61 and the rest of the package 40). In this way, the usermay grasp the pull tab 22, 32 and use it to pull the resealable flap 42away from the package body 48 of the package 40, as illustrated in FIGS.4-5 .

These and other modifications and variations to the present inventionmay be practiced by those of ordinary skill in the art, withoutdeparting from the spirit and scope of the present invention, which ismore particularly set forth in the appended claims. In addition, itshould be understood that aspects of the various embodiments may beinterchanged in whole or in part. Furthermore, those of ordinary skillin the art will appreciate that the foregoing description is by way ofexample only, and is not intended to limit the invention so furtherdescribed in such appended claims. Therefore, the spirit and scope ofthe appended claims should not be limited to the description of theversions contained therein.

What is claimed is:
 1. A roll of flexible packaging film which isconfigured to be cut into individual packages, the roll of flexiblepackaging film comprising: a first film layer; and a second film layerat least partially releasably affixed to the first film layer via apressure sensitive adhesive layer to form a laminate having a width anda length, wherein the length is greater than the width; the pressuresensitive adhesive layer comprising: at least one adhesive zone, and atleast one adhesive-free zone, wherein the at least one adhesive-freezone extends partially across the width and continuously along theentire length of the roll of packaging film; wherein the second filmlayer comprises at least one pull tab which is disposed within the atleast one adhesive-free zone.
 2. The roll of flexible packaging film ofclaim 1, wherein the first film layer comprises at least one cavitywhich is disposed within the at least one adhesive zone.
 3. The roll offlexible packaging film of claim 1, wherein the first film layercomprises at least one cavity which is disposed adjacent the at leastone adhesive-free zone.
 4. The roll of flexible packaging film of claim1, wherein the film layer is scored to form at least one resealable flapcontinuous with the at least one pull tab.
 5. The roll of flexiblepackaging film of claim 4, wherein the resealable flap may be separatedfrom the first film layer and resealed to the first film layer, via thepressure sensitive adhesive.
 6. The roll of flexible packaging film ofclaim 1, wherein the at least one adhesive-free zone is disposed in theapproximate center of the laminate width.
 7. The roll of flexiblepackaging film of claim 6, wherein at least two cavities are scored inthe first film layer, each cavity being disposed adjacent to oppositesides of the at least one adhesive-free zone.
 8. The roll of flexiblepackaging film of claim 7, wherein the second film layer is scored toform at least two resealable flaps continuous with at least two pulltabs.
 9. The roll of flexible packaging film of claim 8, wherein the atleast two resealable flaps are resealably affixed, via the pressuresensitive adhesive layer, to a portion of the first film layer definingthe at least two cavities.
 10. The roll of flexible packaging film ofclaim 7, wherein the at least one adhesive-free zone is disposed betweenthe two cavities and has a width which is less than the distance betweenthe two cavities.
 11. The roll of flexible packaging film of claim 1,wherein the at least one adhesive-free zone is disposed left or right ofcenter of the film layer.
 12. The roll of flexible packaging film ofclaim 1, additionally comprising tamper-evident indicators.
 13. The rollof flexible packaging film of claim 1, wherein the roll of flexiblepackaging film comprises a plurality of flexible packaging structuresconfigured to be separated from one another.
 14. A method for forming aflexible packaging comprising: providing a first film layer; providing asecond film layer; laminating the first film layer to the second filmlayer using a pressure sensitive adhesive to form a laminate having alength and a width wherein the length is greater than the width, whereinthe pressure sensitive adhesive is applied such that it creates anadhesive zone and at least one adhesive-free zone between the base layerand the film layer, and wherein the at least one adhesive-free zoneextends along the entire length of the laminate, scoring the second filmlayer to form at least one pull tab within the adhesive-free zone and atleast one resealable flap which is continuous with the at least one pulltab; and scoring the first film layer to form at least one cavity. 15.The method of claim 14, wherein the adhesive zone is pattern applied toavoid the adhesive-free zone.
 16. The method of claim 14, wherein thepressure sensitive adhesive is applied throughout the first film layerand second film layer and wherein the pressure sensitive adhesive ispartially deactivated to create the adhesive-free zone.
 17. The methodof claim 14 additionally comprising scoring along the length of thelaminate, between at least some adjacent resealable flaps and cavities,to form separate packaging structures.
 18. The method of claim 14,wherein the at least one adhesive-free zone is disposed left or right ofcenter of the film layer.
 19. The method of claim 14, wherein the atleast one adhesive-free zone is disposed in the approximate center ofthe laminate width.
 20. The method of claim 19, wherein at least twocavities are scored in the first film layer, each cavity being disposedadjacent to opposite sides of the at least one adhesive-free zone.